Perimeter foundation panel, and method of use

ABSTRACT

One embodiment of a Perimeter foundation panel with a leveler (FIG.  7 B) for the use in constructing a foundation wall assembled in plurality to affix a building structure to land. The panels erect on manufactured levelers, which create a freestanding foundation (FIG.  1 ) wall that adjust vertically before encasement. Formed from a single sheet of material (FIG.  3 ); cut in a pattern that comprise a top rail ( 1 ), bottom rail ( 2 ), top rim ( 5 ), bottom rim ( 6 ), a right tab ( 3 ) a left tab ( 4 ) and a flat smooth face ( 7 ). After fabrication vertical Z braces ( 14 ) are rigidly affixed in plurality with-in the cavity of the panel. C brace ( 16 ) installing at the inside of tab ( 3 , or  4 ) of adjoining panel. Constructed within a footer void ( 24 ) and cast in-situ.

CROSS-REFERENCE RELATED APPLICATION

This application claims the benefit of provisional patent application Ser, No. 60/802,537, filed 2006 May 22 by the present inventor.

FEDERALLY SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to the building industry, specifically to the perimeter foundation

2. Prior Art

Building foundations are required for all structures. The classic method is to construct a self standing foundation, then construct or install a building onto it. This method is preferred, correcting the natural undulation within the building. Although the technique is preferred; the materials are flawed

U.S. Pat. No. 6,205,725 to Butler (2001) and incorporated herein by reference discloses an interlocking corrugated fluted panel that assembled in plurality, hung by an existing structure, and cast in-situ. In other words the panels are pre-hung from the existing building relying on the sill to hold the weight of the panel prior to casting. Thus, it is not self-standing

Further, it evades the natural load transfer of gravity that occurs when a structure is set upon, or built upon a self-standing foundation. Also the foundation mirrors the structures flaws with in the building such as undulation. Undulation occurs when a structure moves across various terrains. Distortion of the structure occurs thus, creating tension and stress on the windows, doors, cabinets, floors, joints and seams. Consequently, the use of this foundation locks-in the undulation with no way to correct it. Some manufactures of the housing industry have denounced the use of this and voids warrantees.

Further, the detail of the interlocking flute is flawed. The panel more accurately rests one edge of the flute into and onto the next. There is no rigid attachment to the adjacent panel prior to cast and thus waves, along the lateral plane, exist.

U.S. Pat. No. 6,205,720 to Wolfrum incorporated herein by reference discloses a prefabricated foundation panel attaches to a pre cast concrete footer. This requires various degrees of skill and is expensive along with numerous building inspections. Further, the panel has a decorative coated facing that has no shear force or load bearing properties. In addition, numerous components comprise the panel leaving it vulnerable to failure. Failures can occur due to manufacturing, inferior quality and exposure to critical areas.

The large majorities of all building foundations are either poured concrete or cinder block. Poured concrete and cinder block wall foundations are not with out problems, they frequently fail. The failures are consistent with the soil conditions and environment. Dramatic temperature change along with soil saturation, soil erosion, excessive water-bearing soil, and ground vibrations are some of the contributors. Ground vibration can be caused by mechanical means such as road traffic, construction, un-natural phenomenon (such as an explosion), and earth quakes, Another cause of failure can be attributed to a rapid undermining of surrounding soils due to floods, poor construction, or design.

Several types of peering foundations for the mobile homes and manufactured homes exist. U.S. Pat. No. 6,550,199 to Phillips (2003) incorporated herein by reference, U.S. Pat. No. 6,256,940 to MacKarvich (2001) incorporated herein by reference, U.S. Pat. No. 6,536,170 to Stuever (2003) incorporated herein by reference, are all systems that support the structures “I” beam only. The I beam is the load carrying frame of the building. The frame is typically made of steel. With respect to all of these foundations the peripheral of the structure has not been addressed which requires further expense.

SUMMARY

In accordance with one embodiment, a prefabricated foundation panel created from singular uniform sheet of metal, formed into a completed panel comprising of a top rail and rim, bottom rail and rim, a right and left side tab, and a front. The general shape of the panel is rectangular with a possible height of 14 feet and a possible width of 14 feet. However; due to the properties of the metallic material, the panel may be radius or angled. As well a metal “Z” braces of the same or lighter gauge spaced in vertical plurality at the required dimension needed for the load specification; Ridgley affixed at the top rim, bottom rim, and front of the panel. A metal C brace of the same gauge or lighter installed at each seam vertically. The panel is erected on adjustable leveler stands rigidly affixed to the bottom rail in plurality and rigidly affixed to adjacent panel with-in the void of the footer trench and cast in-situ, thus; creating a single uniform load bearing foundation structure.

DRAWING—FIGURES

FIG. 1 is a view of the foundation interior

FIG. 2 is a view of the cross section of the panel while in the footer.

FIG. 3 is a view of the panel prior to formation

FIG. 4 is a magnified view of the vent

FIG. 5 is a view of the panel after formation

FIG. 6A is a view of the inside of the foundation with Z brace prior to C brace and leveler.

FIG. 6B is a view of the panel with the Z brace, C Brace, and leveler assembled

FIG. 7A is a view of the leveler before being assembled

FIG. 7B is a view of the leveler after being assembled

DRAWING—REFERENCE NUMERALS

 1 top rail  2 bottom rail  3R right side tab  3L left side tab  5T top rim  5B bottom rim  7 face of panel  8 hole 12 vent 14 Z brace 16 C brace 18 nut 20 bolt 22 washer 24 footer floor 26 threaded rod 28 resting top plate 30 bottom plate 28A resting top plate flange 30A bottom plate tab 34 building 36 concrete 38 lag bolt 40 earth 42 locking plate 44 rivet 46 45 degree cut 48 seam

DETAILED DESCRIPTION First Embodiment

FIG. 1 is a view of the foundation panel FIG. 6B from the backside of the foundation during assembly.

Panel FIG. 6B fabricated from a single sheet of galvanized steel. FIG. 3 is the pre-formed galvanized steel sheet with an average thickness of 0.079 inches (14 gauge). Cut into a pattern that comprises of a top rail 1, bottom rail 2, a right side tab 3R and left side tab 3L, and a top rim 5T and a bottom rim 5B thus; leaving the balance of the sheet as the face of the panel 7. However, panel FIG. 6B can be of any suitable material that meets load and lift requirements and the thickness of the steel can be heavier or lighter depending on the load specification.

Panel FIG. 5 is the formed panel after top rail 1, and bottom rail 2 are bent perpendicular to the face of the panel in the same direction. Additionally; tab 3R and tab 3L are bent all in the same direction as the top and bottom rails, and are perpendicular to the face 7. Finally, the top rim 5T and bottom rim 5B are bent perpendicular to the top 1 and bottom 2 rails towards each other. FIG. 5 is of a rectangular shape.

Panel FIG. 5 is rigidly fastened in to shape by joining the 45° degree cuts 46 on the side, 3R top and bottom, and tabs 3L top and bottom. This is done by placing the locking plate 42 on the inside of tab 3L and 3R, straddling the seam line 48 and rigidly affixing the locking plate 42 to the inside of the tab 3R and 3L by the use of locking rivets 44. In other words, the rivet inserts through the outside of the steel into the locking plate.

FIG. 4 is a magnified view of the vent 12 detail. The vent 12 is directly machined into the panel leaving the surface smooth. The diameter of the vent holes 12A is determined by the required airflow specification. The vent 12 is machined into the panel in a lateral plane commencing at a minimal one inch below the top rail 1 running parallel maintaining the minimal one-inch distance for a length determined by the required specification. The vent 12 descends longitudinally down the face of the panel. The distance of the longitudinal plane is determined by the required square feet of vent. Both the length distance and the height distance of vent 12 will be in relation to the square footage of the building 34 and the required airflow.

The Panel FIG. 5 has the benefit of using the leveler FIG. 7B. The leveler allows for correcting the horizontal plane of the panel 6B in the completed foundation prior to casting in concrete. In other words, the foundation panel levels by adjusting the nuts 18 on the threaded rod 26.

The leveler FIG. 7B benefits from a simple design. FIG. 7A shows the top resting plate 28 and the bottom plate 30 have flanges 28A and 30A for attachment with matching guide holes not numbered. The top plate flange 28A slides down the inside vertical face of the bottom plate flange 30A until the guide holes line up and can receive the stabilizer bolt 20A. Further, a threaded rod 26 along with nuts 18 and washer 22 attaches the bottom plate 30 to the top plate 28 through mirrored hole not numbered thus, creating an adjustable stand FIG. 7B for the panel FIG. 5

The panel FIG. 5 has the advantage allowing for the addition of vertical Z brace 14 with in the panel cavity in plurality rigidly affixed to the top rim 5, bottom rim 6 and face 7 by the means of a locking rivet 44 for added gravity and lateral load requirements.

FIG. 6A shows the addition of the C brace 16 into the panel cavity. This is achieved by placing the face of the C channel against the inside face of the side tabs 3R and 3L. While securing to the adjoining panel FIG. 6B.

FIG. 1 shows the complete formed panel FIG. 6B in process of assembly within the footer void 24 resting upon the leveler FIG. 7B, assembled in plurality whereas encompassing the periphery prior to cast and attachment of the structure 34. The panels align side by side in plurality resting upon the leveler FIG. 7 b in succession. The panels rest on the adjacent panels leveler FIG. 7B while bolting together FIG. 6A. This process continues until the foundation is complete and a uniform foundation exists.

It can be appreciated and is shown in drawings although hard to see FIG. 1 that the leveler FIG. 7B is offset on the panel thus, leaving a resting area for the adjoining panel while it is affixed to the preceding panel. FIG. 6A shows the use of a nut 18 and bolt 20 as the preferred method of ridged attachment of the panels in FIG. 1.

Further, not shown in the drawings is the ability to manipulate the face of the panel FIG. 5. With plurality of reliefs notched into the top rail 1 and bottom rail 2 the panel face 7 can be angled or radius. Corner panels not shown in the drawings are made of the panel FIG. 5 by notching a relief in the top rail 1 and the bottom rail 2 then bent inward 90° degrees and rigidly fixed into shape.

Panel 6B galvanization on the steel should be a minimum “G90” protective coating. Further, not indicated in the drawing commencing the completion, the use of polyurethane based caulk or mastic on the joint creates a watertight seal. Also not shown upon completion of the foundation the use of an emulsified tar, epoxy based paint or a cement coating of no less than 33% Portland cement applied directly to the panel face 7 for increasing the longevity of panel from many soil types.

The concrete depth 36 is in relation to the load and forces requirement.

FIG. 2 is of the cross section of a completed foundation after concrete cast. The building 34 attaches by the use of a lag screw 38. In other words, the drawing depicts a typical construction detail provided for this style of foundation.

Operation—FIG. 1

The manner of using the perimeter panel foundation FIG. 6B for the attachment of a building structure to the earth is achieved by assembling the panel within in the footer void 24 and cast in-situ.

A footer void is created by excavating a specific amount of earth material typically with the use of hand tools such a shovel to a perspective depth determined by the load factors.

The panel FIG. 6B is set into the footer void with the leveler standing on the bottom of the footer. The panel FIG. 6B is then placed side by side to the previous keeping the faces flush.

The panels are lifted off the footer floor 24 via the leveler FIG. 7B, the c brace 16 is then placed into the panel cavity FIG. 1 with the face of the C brace 16 towards the inside; side tab 3L, and the parallel C tabs not numbered heading toward the Z brace 14. A bolt 20 is then placed through the C brace 16 and through the existing panels side tab 3L from the inside of the panel, through the adjoining panel side tab 3R. A nut 18 completes the rigid attachment.

This process repeats longitudinally down the tabs 3L and 3R and C brace 16 until the side tabs of each panel are complete and rigidly fastened down the vertical plane.

A bubble lever or equivalent device checks along the horizontal plain making sure the top rails are level. Adjustments to the leveler stand FIG. 7B is done by releasing the tension on the top nut 18 or in other words, backing the nut up and then turning the opposing nut on the bottom side of the top plate in the direction required for the adjustment. Once the adjustment is satisfied, the top nut is firmly tightened against the inside of the bottom rail FIG. 6B not shown.

The previous process repeats until the entire foundation wall is level. The use of temporary braces made of wood against the face of the panel or in the back, wedged at a 45° degree angle to maintain the vertical plumb plain of the face of the panel.

With the panels level and plumb to each other; concrete 36 pumps into the footer void encasing the base of the panel and the leveler both front and back to become the footing and foundation FIG. 2. After ample time is allowed for the curing of the concrete the building is then to be placed on the foundation or built. By attaching the sill to the top rail via a lag screw 38

Prior to back filling against the wall, a coating is applied comprising of either emulsified tar, rubber based sealant, or a concrete coating. To maintain a watertight joint seam between panels a polyurethane caulking is applied.

Advantages

From the above description, a number of advantages of some of the embodiments of my perimeter foundation panel become obvious.

-   -   (a) The simplicity of the panel allows all skill levels to         assemble the foundation without extensive knowledge or training.     -   (b) The simplicity in the design uses basic hand tools thus not         requiring expensive proprietary devices.     -   (c) The structural integrity is evident with the use of a         singular uniform sheet of metallic material not requiring         attachment of each separate component. The uniform panel has         limited attachment points and a uniform face that integrates         with-in the panel structure adding immense strength to the         panel.     -   (d) The face of the panel acts a structural support for shear         forces, gravity loads, lifting loads and side impact loads.     -   (e) The uniquely designed leveler allows for the vertical         adjustment of the horizontal plain of the panels leading edge         prior to encasement, allowing for an accurately level surface         accepting the sill plate.     -   (f) The method of assembly within the footer void is         advantageous in that the panel becomes an internal component of         the footing and thus creates a uniform structure with unlimited         beneficial strength.     -   (g) The unique method of assembly in the footer void is         advantageous in that the footer void is established and the         panel assembly is the only metallic material required to         comprise the structural integrity of the footer after         encasement, further, no special skill levels are required to         construct the footing.     -   (h) The simplicity in the panel design and method of use reduces         the time need to erect a foundation.     -   (i) The use of the perimeter foundation panel on manufactured         buildings reduces the installation time.     -   (j) The use of the perimeter foundation panel is beneficial in         existing buildings that need foundation wall replacement.     -   (k) The use of the perimeter foundation panel on new         construction reduces the foundation expense whereas steel         material is less expensive.     -   (l) The use of the perimeter foundation panel is easily handled         requiring limited installers     -   (m) The encasement of the panel allows for future conversions of         the building by easy detachment of the panel.

CONCLUSION, RAMIFICATION AND SCOPE

Accordingly, the reader will see that the perimeter foundation panel of various embodiments provides a more reliable prefabricated panel with limited skill requirement, comprised of light weight alternative to block or concrete, yet less expensive, free standing, that is an accelerated assembly, and adaptable for any building requiring a foundation.

While my above description contains many specificities, these should not be construed as limitation on the scope of the invention, but rather as an exemplification of several preferred embodiments thereof. Many other variations are possible. For example

-   -   The leveler can be changed or removed     -   The thickness of the material can be changed     -   The material composition of the panel can be changed     -   The face of the panel can have various facade     -   The shape of the panel can change     -   The design of the leveler can be modified     -   The method of securing the shape can change     -   The method of attachment to sill can change     -   Addition of alternative structural beams and supports     -   Encasement methods can change     -   Encasement materials can change     -   C brace can be changed or removed or added     -   Z brace can be changed or removed or added 

1. A perimeter foundation panel system for anchoring building to the earth to support the floor sill of a building, the panel comprising: a uniform panel rectangular generally elongate, including parallel top and bottom rails, outermost tabs joining top and bottom rails, top and bottom inner rims having a metallic composition with a brace installed in the cavity running longitudinally from the top rail to the bottom rail in plurality, having a C brace installed at one end of the panel supporting the joining panel seam, erected on a leveling device in the footer void and cast in-situ.
 2. The apparatus of claim 1 being of a solitary sheet of metallic material, cut to a pattern consisting of a top rail and rim, a bottom rail and rim, a right tab and left tab, and a face.
 3. The apparatus of claim 2 wherein said bent to form the top and bottom rim are downward with the leading edge facing each, the top and bottom rails are bent in a manner to make them parallel and perpendicular to the face, the right and left side tabs are bent parallel in the same direction as the top and bottom rail.
 4. The apparatus of claim 2 is rigidly fasten into shape along the longitudinal face of the right and left side tab and the top and bottom right and left side tab with an appropriate mechanism competent to affix the joining plains.
 5. The apparatus of claim 2 has Z bracing installed into the cavity running longitudinally in plurality from the top rail to the bottom rail rigidly affixed to the top and bottom rim in the panel cavity and rigidly affixed to the face of the panel running longitudinally down the face in a symmetric position.
 6. The perimeter foundation panel 2 having installed components consisting of a Z braces will have a C brace firmly attached to the side tab upon assembly to another panel, by the means of a nut and bolt, the C brace face is flat against the inside face of the said side tab with the one parallel tab flush to the face of the panel and the other C brace tab flush to the top and bottom rim.
 7. The apparatus of claim 1 leveling device comprises of a top resting plate that has a bent stop-tab at the front facing upward to the top of the panel and an opposing bent stabilizer tab at the back facing downward from the panel with an elliptical cut; the bottom plate has a stabilizer tab at the back bent facing upward to the top plate tab with an elliptical cut and a bent tab in the front facing upward, the two plates are conjoined by fixing through the elliptical relief's when aligned, the use of a fastening device of essential length inserts through a hole in the top plate that is mirrored in the bottom plate and securely fastened to the upper plate and bottom plate with the balance of the fastening device fixed to the bottom of the panel.
 9. The apparatus of claim 1 wherein comprising of is provided with vent holes
 10. The methods of assembly and anchoring the building to the earth comprising (a) excavating a peripheral foundation footer void within said portion of the earth, said trench being in relation to the building peripheral equal to the length and width, and designed for predetermined load factors (b) wherein the perimeter foundation panel is assembled within said footer void and rigidly attached to the preceding panel in plurality encompassing the footer void, (c) the footer void is filled with a flowable hardenable building material encompassing a portion of the assembled perimeter panel foundation for anchorage, (d) a building is implemented on the foundation wall, (e) rigid attachment to the building with a suitable anchor. 